Valves and pumps using said valves

ABSTRACT

Improved, rigid valves for pumps include outlet valve portions having a valve seal portion and one or more surfaces which create pockets between the outlet valve and an interior wall of a pump to collect and trap particulates in a formulation being pumped.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of, and claims the benefit ofand priority to, U.S. application Ser. No. 13/689,136, entitled “VALVESAND PUMPS USING SAID VALVES,” filed 29 Nov. 2012, and incorporates thesame herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention relate to valves for pump devices and moreparticularly to improved valves having both inlet and outlet components.

2. State of the Art

The personal and beauty care markets utilize a wide variety of differentpump mechanisms and devices for delivering fluid-based product to auser. Such pump devices include traditional pumps using ball valves orflap valves. Unique pump devices may also increase the aesthetic valueor appeal of the pump device or provide unique functionality to a pumpdevice. For example, as illustrated and described in WO2010/117754,which is incorporated herein in its entirety by reference, a pump mayinclude a base having an inlet passage, an interior chamber, and adischarge passage. A valve having a valve stem, an outlet valve at oneend of the valve stem and an inlet valve or valve disc at an oppositeend of the valve stem, may be seated in the base such that the outletvalve may open and close a passage through the discharge passage and theinlet valve or valve disc may open and close a passage from a containerinto the interior chamber of the base.

A pump 300 as described in WO2010/117754 is illustrated in FIG. 1 andthe components thereof are illustrated in FIGS. 2A through 2D. Inparticular, a pump 300 may include a base 310 having an inlet passage312, an interior chamber 314, and a discharge passage 318 A valve 330may be positioned in the base and may include a valve stem 333, anoutlet valve 339 at one end of the valve stem 333 and engaged with thedischarge passage 318 in a closed position, and a valve disc 336 at avalve stem 333 end opposite the outlet valve 339, engaged with or actingas an inlet valve in the inlet passage 312. A bellow 350 may be securedto the base 310 with a cap 380. The base 310 may be secured to anattachment adapter 325 or container.

While the pumps and assemblies illustrated and described inWO2010/117754 may provide sufficient operation, one draw-back is therigidity or stiffness of the valve used therewith, which can impactperformance and assembly of a pump. Thus, improvements to such pumps andthe valves used with such pumps are desirable.

BRIEF SUMMARY OF THE INVENTION

According to certain embodiments of the invention, a valve for a pumpassembly may include an improved valve stem. According to certainembodiments of the invention, a valve stem may be improved by providinga thicker cross-sectional area than used with prior valve devices.According to other embodiments of the invention, a valve stem may beimproved by providing a geometric shaped cross-sectional area such thatthe geometric shape may provide increased stiffness to the valve and thevalve stem.

According to still other embodiments of the invention, an improved valvemay include an outlet valve portion having a conical shape. In someembodiments of the invention, a conically shaped outlet valve may beconfigured to seat in a conically shaped discharge passage of a pumpbase.

According to other embodiments of the invention, an improved valve mayinclude both art improved valve stem configuration and an improvedoutlet valve. For example, an improved valve according to variousembodiments of the invention may include a conical outlet valve and avalve stem having a width substantially similar to the largest diameterof the conical outlet valve. In other embodiments, an improved valve mayinclude a conical outlet valve and a valve stem having a cross-shapedcross-sectional area. In still other embodiments, an improved valve mayinclude a conical outlet valve and a valve stem having one or moresupport ribs running at least a partial length of the valve stem.

According to still other embodiments of the invention, an improvedoutlet valve may include one or more steps in the outlet valve portion.An outlet valve having one or more steps may allow the collection ofparticulate matter in the regions of the one or more steps so that suchparticulates do not hinder operation of the outlet valve.

According to still other embodiments of the invention, an improvedoutlet valve may include a valve seal portion seated against an interiorwall of a pump, one or more surfaces extending from the valve sealportion towards a valve stem, and a pocket formed between the outletvalve and an interior wall of a pump in which the outlet valve isseated.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming particular embodiments of the present invention,various embodiments of the invention can be more readily understood andappreciated by one of ordinary skill in the art from the followingdescriptions of various embodiments of the invention when read inconjunction with the accompanying drawings in which:

FIG. 1 illustrates a pump and valve according to the prior art;

FIGS. 2A through 2D illustrate components of a pump according to variousprior art embodiments;

FIG. 3 illustrates a valve according to various embodiments of theinvention;

FIG. 4 illustrates a cross-sectional view of a valve along its lengthaccording to various embodiments of the invention;

FIG. 5 illustrates a front view of a valve according to variousembodiments of the invention;

FIG. 6 illustrates a rear view of a valve according to variousembodiments of the invention;

FIG. 7 illustrates a valve according to various embodiments of theinvention;

FIG. 8 illustrates a cross-sectional view of a valve along its lengthaccording to various embodiments of the invention;

FIG. 9 illustrates a cross-sectional view of a valve along its widthaccording to various embodiments of the invention;

FIG. 10 illustrates a perspective view of a valve according to variousembodiments of the invention;

FIG. 11 illustrates a cross-sectional view of a pump including a valveaccording to various embodiments of the invention.

FIG. 12 illustrates a perspective, component view of a pump including avalve according to various embodiments of the invention;

FIG. 13 illustrates a perspective, component view of a pump including avalve according to various embodiments of the invention;

FIG. 14 illustrates a side view of a valve according to variousembodiments of the invention;

FIG. 15 illustrates a cross-sectional side view of a valve along itslength according to various embodiments of the invention;

FIG. 16 illustrates a perspective view of a valve according to variousembodiments of theinvention;

FIG. 17 illustrates an enlarged front view of the valve illustrated inFIG. 14;

FIG. 18 illustrates an enlarged side view of an outlet valve portion ofa valve according to various embodiments of the invention;

FIG. 19 illustrates an enlarged perspective view of an outlet valveportion of a valve according to various embodiments of the invention;

FIG. 20 illustrates a cross-sectional view of pump including a valveaccording to various embodiments of the invention;

FIG. 21 illustrates an enlarged view of the outlet valve portion of thevalve in the pump illustrated in FIG. 20;

FIG. 22 illustrates a perspective, component view of a pump including avalve according to various embodiments of the invention; and

FIG. 23 illustrates a valve and multiple outlet valve configurations fora valve according to various embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

According to embodiments of the invention, a valve 130 for a pump mayinclude a valve stem 133, an outlet valve 139 and a valve disc 136. Theoutlet valve 139 and valve disc 136 may be on opposite ends of the valvestem 133.

A valve 130 according to various embodiments of the invention isillustrated in FIGS. 3 through 6. As illustrated, a valve 130 mayinclude a valve stem 133 having an outlet valve 139 adjacent one endthereof and a valve disc 136, or inlet valve, located on an end of thevalve stem 133 opposite the outlet valve 139. The outlet valve 139 maybe rounded or have a circular or oval shape. According to variousembodiments of the invention, a diameter of the outlet valve 139 may beconfigured or selected such that the outlet valve may seat against adischarge passage 318 of a pump to prevent discharge of a product fromthe pump until the valve stem 133 is moved, resulting in an unseating ofthe outlet valve 139 from a discharge passage 318.

According to some embodiments of the invention, a valve stem 133 mayextend from the outlet valve 139 to a valve disc 136 at an opposite endthereof. A valve stem 133 may include a cross-sectional portion having awidth as large as a diameter of the outlet valve 139 over at least aportion of the valve stem 133. At a portion of the valve stem 133nearing the valve disc 136, the valve stem 133 may narrow or convergetowards a central portion of the valve disc 136. For example, the valve130 illustrated in FIGS. 3 through 6 includes a valve stem 133 having across-sectional width equal to the largest diameter of the outlet valve139 over a portion of the valve stem 133. At a point near the valve disc136, the valve stem 133 narrows or converges towards a central portionof the valve disc 136, creating a narrowed region in the valve stem 133adjacent the valve disc 136.

As shown in the cross-sectional view of FIG. 4, the cross-sectional areaof the valve stem 133 remains as thick as the cross-sectional diameterof the outlet valve 139 across a large portion of the valve stem 133.Only nearer the valve disc 136 does the cross-sectional area of thevalve stem 133 begin to decrease or narrow.

FIG. 5 illustrates a front view of the valve 130 illustrated in FIGS. 3and 4 and FIG. 6 illustrates a rear view thereof. As illustrated, thediameter of the valve stem 133 at a forward portion of the valve stem133 nearest the outlet valve 139 is greater than at the point where thevalve stem 133 joins with the valve disc 136.

According to various embodiments of the invention, a valve 130 having athicker valve stem 133—or a valve stem 133 with an initial width orshape equivalent to a cross-sectional area of the outlet valve 139—witha narrowing of the valve stem 133 adjacent to the valve disc 136provides a stiffer or more rigid valve 130 than those of the prior art.

According to some embodiments of the invention, a valve stem 133 may beconfigured or shaped such that the cross-sectional area or width of themajority of the length of the valve stem 133 relative to thecross-sectional area or width of the valve stem 133 at the point ofconvergence with the valve disc 136 provides a desired force to resistmovement of the valve stem 133 relative to the valve disc 136. In thismanner, the force required to open an outlet valve 139 may be adjustedby changing the configuration of the valve stem 133 thickness along thevalve stem 133 and at the point of convergence with the valve disc 136.

A valve 130 according to other embodiments of the invention isillustrated in FIGS. 7 through 9. As illustrated, a valve 130 may haveone or more ribs 190 or other stiffing features running along alength—or part of a length—of the valve stem 133. In other embodiments,ribs 190 or stiffening features may run along portions of the width orcircumference of a valve stem 133.

According to various embodiments of the invention, a valve stem 133 mayinclude four ribs 190 running along a portion of a length thereof asillustrated in FIG. 7. The ribs 190 may extend from the outlet valve 139end of the valve 130 towards the valve disc 136. Adjacent to the valvedisc 136, the ribs 190 may narrow or converge towards the valve disc 136as illustrated.

A cross-sectional view of the valve stem 133 and ribs 190 is illustratedin FIG. 9. As illustrated, the valve stem 133 and ribs 190 may form across shape or “X” shape. In other embodiments of the invention, two orthree ribs 190 could be used instead of four. In addition, more thanfour ribs 190 could be used with various embodiments of the invention.

In still other embodiments of the invention, portions of the exteriorsurface of the ribs 190 may be configured such that they contact thewalls of a base 310 when assembled with a base 310 of a pump. Suchcontact may provide further stability or may be used for assemblypurposes to guide a valve 130 into a desired assembled position. Instill other embodiments of the invention, one or more support ribs maybe configured as part of a valve stem 133, or on a valve stem 133, insuch a manner that when assembled with a base 310 of a pump, at leastsome of the one or more support ribs 190 contact a portion of aninterior chamber of the base. During actuation of the pump and movementof the valve 130, contact between those portions of the valve stem 133and the walls of the interior chamber of the base 310 may preventflexion or movement in a direction other than parallel to the axisthrough the pump base 310 from the inlet orifice to the dischargepassage 318.

According to some embodiments of the invention, a valve 130 having ribs190 may provide a more rigid valve 130 than those of the prior art.

According to various embodiments of the invention, a valve stem 133 of avalve 130 may be shaped or configured to provide increased rigidity tothe valve 130. For instance, a valve stem 133 may be a solid valve stem133 having a narrowing portion adjacent a valve disc 136. In otherembodiments, a valve stem 133 may include shaped features or ribs 190running along a length or width of the valve stem 133 to providesupport, rigidity, and stiffness to the valve stem 133 and the valve130. In still other embodiments of the invention, the rigidity orstiffness of a valve 130 may be increased by utilizing a valve stem 133shape which narrows as the valve stem 133 approaches a valve disc 136.Ribs 190 or other features may be added to the valve stem 133 toincrease the rigidity or stiffness of the valve 130.

A valve 130 according to still other embodiments of the invention isillustrated in FIGS. 10 and 11. As illustrated in FIG. 10, a valve 130may include a conical outlet valve 139. Although rounded outlet valvesmay be used with various embodiments of the invention, it has been foundthat the use of a conical outlet valve 139 with a pump base 310 having acorresponding conical shaped discharge passage 318 provides a betterseal or valve seat. Thus, in certain embodiments of the invention, avalve 130 may have a conically shaped outlet valve 139.

A pump assembled with a valve according to various embodiments of theinvention is illustrated in FIG. 11. As illustrated, the pump mayinclude a base 310 having a discharge passage 318. A valve 130 may beseated in the base 310 such that the outlet valve 139 seats against thedischarge passage 318. An attachment adapter 325 may fit in an oppositeend of the base 310 and secure the valve 130 within the base 310. Inaddition, the attachment adapter 325 may provide an inlet valve seatwhich mates with or contacts at least a portion of the valve disc 136 toprovide an inlet valve for the pump from a container or pouch attachedto the base 310 of the pump. A bellow 350 may be secured to the base 310with a cap 380. Actuation of the bellow 350 with product in the base 310may apply a force against the valve disc 136, which in turn may apply aforce to the valve stem 133 and unseat the outlet valve 139 from thedischarge passage 318, allowing product to flow from the pump as known.

As illustrated in FIG. 11, a valve 130 having a conically shaped outletvalve 139 is seated in a conically shaped discharge passage 318 of apump base 310. The seat of the conical shaped outlet valve 139 may bematched to the discharge passage 318 to provide a superior seal. Inaddition, it has been found that the use of a conical shaped outletvalve 139 as illustrated may provide an improved discharge of product.This is especially true where the valve 130 is a stiffened valveaccording to embodiments of the invention. For example, when using avalve 130 according to embodiments of the invention having a conicalshaped outlet valve 139, discharge of a product front the pump is morecontrolled. The conical shape of the outlet valve 139 and correspondingshape of the discharge passage 318 provides an improved valve seat whichstabilizes the flow of product out the discharge valve and provides acleaner shut-off when the outlet valve 139 re-seats with the dischargepassageway 318.

A pump assembly according to various embodiments of the invention isillustrated in FIG. 12. As illustrated, a pump may include a base 310, avalve 130 fitted in the base 310, an attachment adapter 325 fitted intothe base 310 to secure the valve 130 therein, and a bellow 350 securedwith a cap 380. In some embodiments of the invention, a base 310 mayinclude a canoe shaped attachment for securing the pump to a pouch orother container. A valve 130 incorporated with—or assembled in—the pumpmay include a stiffened or rigid valve 130 according to embodiments ofthe invention. In addition, a valve 130 may include a conically shapedoutlet valve 139 portion as illustrated.

A pump assembly according to various embodiments of the invention isillustrated in FIG. 13. As illustrated, a pump may include a base 310, avalve 130 fitted in the base 310, an attachment adapter 325 fitted intothe base 310 to secure the valve 130 therein, and a bellow 350 securedwith a cap 380. In some embodiments of the invention, a base 310 mayinclude a canoe attachment having a curved shape for securing the pumpto a pouch or other container. A valve 130 incorporated with—orassembled in—the pump may include a stiffened or rigid valve 130according to embodiments of the invention. In addition, a valve 130 mayinclude a conically shaped outlet valve 139 portion as illustrated.

A valve 230 according to still other embodiments of the invention isillustrated in FIGS. 14 through 17. A valve 230 may be used in a pumpand may include a valve stem 233, an outlet valve 239 and a valve disc236. The outlet valve 239 and valve disc 236 may be on opposite ends ofthe valve stem 233.

As illustrated in FIG. 14, a valve 230 may include one or more ribs 190or other stiffing features running along a length—or part of a length—ofthe valve stem 233. In other embodiments, ribs 190 or stiffeningfeatures may run along portions of the width or circumference of a valvestem 233.

According to various embodiments of the invention, a valve stem 233 mayinclude four ribs 190 running along a portion of a length thereof. Inother embodiments three or more ribs 190 may be used. For example, avalve 230 may include three ribs 190, four ribs 190, five ribs 190 ormore running along a length of a valve stem 233. The ribs 190 may extendfrom the outlet valve 239 end of the valve 230 towards the valve disc236. Adjacent to the valve disc 236, the ribs 190 may narrow or convergetowards the valve disc 236 as illustrated. Convergence of the ribs 190may be in a conical shape narrowing to a cylindrical portion between theribs 190 and the valve disc 236 or in any other desired configuration.In some embodiments, ribs 190 may provide rigidity or support to thevalve 230.

According to various embodiments of the invention, an outlet valve 239portion of the valve 230 may include one or more steps or surfaceshaving different angles compared to other surfaces making up the outletvalve 239 portion of the valve 230. For example, as illustrated in FIGS.18 and 19, an outlet valve 239 may include a valve seal portion 240 at aforward end of the outlet valve 239. One or more surfaces 242 may extendfrom the valve seal portion 240 towards the valve stem 233 and jointherewith. While the illustrated surfaces 242 in FIGS. 18 and 19 includetwo sloping surfaces, an outlet valve 239 may include one or more suchsurfaces extending or sloping away from the valve seal portion 240.

According to various embodiments of the invention, when a valve 230having an outlet valve 239 according to certain embodiments of theinvention is inserted into a base 310 of a pump, the valve seal portion240 may contact an interior wall of the base 310 of the pump at or neara discharge passage 318 of the base 310 as illustrated in FIG. 20. Thevalve seal portion 240 may contact the base 310 in such a way that thedischarge passage 318 is closed or sealed by the outlet valve 239 suchthat product from within the pump cannot escape through the dischargepassage 318. In addition, one or more pockets, gaps or openings may beformed between the outlet valve 239 and the inner wall of the base 310adjacent to the valve seal portion 240. For example, FIG. 21 illustratesa blown-up view of the discharge passage 318 and outlet valve 239illustrated in FIG. 20. As shown, the valve seal portion 240 of theoutlet valve 239 seals against an interior wall of the base 310 near thedischarge passage 318 to prevent product from escaping the pump. Thevalve seal portion 240 extends from its seal with the interior wall ofthe base 310 towards the valve stem 233 and meets the first of twosurfaces 242. The surfaces 242 may be configured to provide or form oneor more pockets 241, spaces or openings between the outlet valve 239 andthe interior wall of the base 310.

The use of a valve 230 having an outlet valve 239 configured to providea seal between a valve seal portion 240 and an interior wall of a base310 of a pump, along with the inclusion of one or more pockets 241 maybe advantageous when used with product formulations having particulatematter therein. For example, it has been found that use of a valve 130having a cone shaped outlet valve 139 such as that illustrated in FIG.10 with products containing particulates may lead to some of theparticulates being trapped between the sealing surface of the coneshaped outlet valve 139 and the interior wall of the base 310 of thepump. When such particulates become trapped, there is an increased riskof a seal between the outlet valve 139 and the base 310 not being madeand air entering the pump or a loss of prime resulting from air enteringthe pump chamber past the outlet valve 139. However, the use of anoutlet valve 239 as illustrated in FIGS. 18 through 21 avoids theseissues and forms abutter seal. In part, the one or more pockets 241 mayallow the valve seal portion 240 to squeeze particulates back into theone or more pockets 241 such that the valve seal portion 240 is able toform a complete seal with the interior wall of the base 310 of the pump.The one or more pockets 241 may provide additional space into whichparticulates may congregate as the valve seal portion 240 seals againstthe interior wall of the base 310 instead of being pinched between thevalve seal portion 240 and the interior wall of the base 310.

According to various embodiments of the invention, an outlet valve 239may include a valve seal portion 240 and one or more surfaces 242extending away from the valve seal portion 240 towards the valve stem233 such that when the outlet valve 239 is seated in or near a dischargepassage 318 of a pump, the outlet valve 239 creates a seal between theinterior wall of a pump and the valve seal portion 240, one or morepockets 241, and a restricted space smaller than the one or more pockets241 interior to the one or more pockets 241.

A pump assembly according to various embodiments of the invention isillustrated in FIG. 22. As illustrated, a pump may include a base 310, avalve 230 which may be inserted into the base 310, an attachment adapter325 fitted into the base 310 to secure the valve 230 therein, and abellow 350 secured to the base 310 by a cap 380. In some embodiments, abase 310 may include a canoe having a straight or winged shape forsecuring the pump assembly to a pouch or container.

An outlet valve 239 according to still other embodiments of theinvention may include one or more ridges 243 encircling all or part ofthe outlet valve 239 as illustrated in FIG. 22. FIG. 22 shows a valve230 without an outlet valve 239 on the end and thirteen alternativeconfigurations for an outlet valve 239 which may be used with variousembodiments of the invention. As illustrated, one or more ridges 243formed on a part of the outlet valve 239 may create pockets, spaces, oropenings that may trap or contain particulates when an outlet valve 239seals against a pump. The one or more ridges may be formed to createpockets 241. In addition, an outlet valve 239 may include one or moreraised bands 247 capable of creating similar pockets, spaces, oropenings relative to an interior of a pump such that particulates may betrapped in the pockets formed between the one or more bands 247 and aninterior wall of a pump. In still other embodiments, one or more holesor divots 245 may be formed in the outlet valve 239 to provide pockets241 between the outlet valve 239 and an interior wall of a pump.

A valve 230 having a particular outlet valve 239 configuration accordingto various embodiments of the invention may be molded as a unitarycomponent using known molding methods.

According to various embodiments of the invention, a valve disc 236 maybe conical in shape as illustrated in FIGS. 3 and 7 or it may be roundedor cup shaped as illustrated in FIGS. 10 and 14. According to someembodiments of the invention, the cup shape of a valve disc 236 may helpfacilitate movement of a valve 130, 230 in a parallel plane when in use.In some embodiments, the configuration of the cup shape may also bealtered to adjust the force required to unseat an outlet valve 139, 239from its seat against the base 310 of the pump.

Valves 130, 230 according to various embodiments of the invention may bemade of a flexible material such as TPE, TPU, silicon or other materialas desired. In addition, valves 130, 230 according to other embodimentsof the invention may be made of a different plastic or resin material.

Having thus described certain particular embodiments of the invention,it is understood that the invention defined by the appended claims isnot to be limited by particular details set forth in the abovedescription, as many apparent variations thereof are contemplated.Rather, the invention is limited only be the appended claims, whichinclude within their scope all equivalent devices or methods whichoperate according to the principles of the invention as described.

What is claimed is:
 1. A valve for a pump, comprising: a valve stem; anoutlet valve at a first end of the valve stem, comprising: a valve sealportion; at least one surface extending from the valve seal portiontowards the valve stem; a valve disc at a second end of the valve stem.2. The valve of claim 1, wherein the valve disc comprises a cup shape.3. The valve of claim 1, wherein the valve disc comprises a conicalshape.
 4. The valve of claim 1, further comprising at least one ribrunning a portion of the length of the valve stem between the outletvalve and the valve disc.
 5. The valve of claim 1, wherein the outletvalve further comprises at least one ridge about a portion of the atleast one surface extending from the valve seal portion towards thevalve stem.
 6. The valve of claim 1, wherein the outlet valve furthercomprises at least one band about a portion of the at least one surfaceextending from the valve seal portion towards the valve stem.
 7. Thevalve of claim 1, wherein the outlet valve further comprises at leastone divot in the outlet valve.
 8. A pump, comprising: a base; a bellowseated in the base; a cap securing the bellow in the base; a valve in aninterior portion of the base, the valve comprising: an outlet valvecomprising a valve seal portion seated against an interior wall of thebase and at least one surface extending into an interior of the base; avalve stem in communication with the at least one surface; a pocketbetween the outlet valve and the interior wall of the base; and a valvedisc at an end opposite the outlet valve; an attachment adapter seatedagainst the valve disc and securing the valve in the base.
 9. The pumpof claim 8, wherein the pocket is between the valve seal portion seatedagainst an interior wall of the base and the valve stem.
 10. The pump ofclaim 8, wherein the outlet valve further comprises at least one ridgeencircling a portion of the outlet valve.
 11. The pump of claim 8,wherein the outlet valve further comprises at least one band encirclinga portion of the outlet valve.
 12. The pump of claim 8, wherein theoutlet valve further comprises at least one divot in the outlet valve.13. The pump of claim 8, wherein the valve disc comprises a cup shapedvalve disc.
 14. The pump of claim 8, wherein the valve disc comprises aconical shaped valve disc.
 15. The pump of claim 8, further comprising aproduct in the pump, the product comprising particulates.